Metal counter top construction



Jan. 30, 1951 cs. H. NORQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 7 Sheets-Sheet 1 15' 24 59 21 INVENTOR.

17/111111 jl flrymisf M M J J 30, 1951 G. H. NORQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 7 Sheets-Sheet 2 INVENTOB. fi/irm ff. Ilia/yams Jan. 30, 1951 H, NORQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 7 Sheets-Sheet 3 INVEN TOR.

// TTO/PNEYJ .Ian. 30, 1951 G. H. NQRQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 7 Sheets-Sheet 4 IN VEN TOR.

(776/111 1% jl/bryaz'sf BY 4%, @aZl/1 Jan. 30, 1951 e. H. NORQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 7 Shee ts-Sheet 5 1314 l=- 1 g I/fl 0 INVENTQR. filmn ff llfm'qansl zirrag/v/zr Jan. 30, 1951 G. H. NORQUIST 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1 94? 7 Sheets-Sheei 6 film J1 Marquis! BY HTTORNEYS Jan. 30, 1951 o u s 2,539,462

METAL COUNTER TOP CONSTRUCTION Filed Feb. 10, 1947 '7 Sheets-Sheet '7 Patented Jan. 30, 1951 7 UNITED STATES PATENT OFFlCE 9 Claims.

This inventionrelates to an improved counter top construction, and more particularly to a metal clad counter top having a raised rim formation extending around the table section thereof and presenting unbroken metal facing surfaces formed of sheet metal supported and reinforced by backing sections of fibrous material.

Metal clad counter tops constructed in accordance with this invention may be formed from a single sheet of light gauge metal stiffened and supported by fibrous backing sections. This improved counter top is characterized by a raised rim formation extending along one or more edges of the table section thereof. The metal facing sheet is formed so as to cover all exposed faces of the counter top free from visible seams, all metal facing surfaces being backed up and supported by fibrous backing selections so that the metal facing surfaces cannot readily be dented or deformed. The metal facing sheet selected is preferably a bright metal, such as stainless steel, Monel metal, aluminum, brass or copper, which may be polished and finished on the top side prior to cutting, shaping and bending thereof.

After the metal facing sheet has been polished, the corners thereof are cut to the proper shape, and a fibrous backing panel then adhesively bonded to the rear, unfinished side of the metal facing sheet. The fibrous backing panel may be formed from laminated plywood, hard pressed fiberboard, composition board or like fibrous sheetings commonly used in the building industry. The fibrous backing panel comprises a table backing section. shaped to be adhesively bonded to the table section of the metal sheet, front and rear apron backing sections designed to be adhesively bonded to the front and rear apron sections of the metal sheet, and side apron backing sections designed to be adhesively bonded to side apron sections of the metal sheet.

The apron backing sections, as bonded to the metal facing sheet, are spaced from the adjacent edges of the table backing section by an open groove of predetermined width. The ends of the apron backing sections are cut on a bevel so that the end faces thereof are sloped at an angle of 45 with respect to its metal attaching face. The elongated edge of each of the apron backing sections, next adjacent the table backing section, is also beveled or sloped with respect to the metal attaching face thereof. The backing panel as bonded to the metal facing sheet, thus presents the apron sections thereof in spaced relation with respect to the table backing section in a manner to permit the formation of the raised rim which is to extend around the edges of the table section of the metal sheet when the counter top construction has been formed.

, fhe metal clad panel is placed in a die press and the peripheral edge portions of the table section of the metal sheet, unsupported by fibrous backing, are formed into a raised rim extending around all of the edges, or a selected number of the edges, of the table section of the metal facing sheet. The open grooves or channels defined between the adjacent edges of the table backing section and the apron backing sections are so spaced and arranged as to permit shaping of the metal clad panel to provide depending apron sections. A bonding adhesive may be applied to the open channels prior to bending formation of the metal clad panel.

The metal clad panel may be shaped into counter top form in a clamping frame which serves to bend the apron sections into position substantially at right angles to the table section. In this forming operation, the longitudinally extending beveled edges of the apron sections will fold over into the open grooves and will be 5 brought into abutment against the rear face of theadjacent raised rim formations of the metal sheet to provide a firm backing support therefor. While the apron sections are still retained in fixed position by the clamping frame, the flange sections of the metal facing sheet are turned inwardly and stiffening strips inserted to fit snugly within the pocket form by the inturned flange sections and the adjacent formed apron sections. The stiffening strips thus provide a rectangular frame which further strengthens the construction. The inturned flange sections may be secured to the stiffening frame as by nails or screws, whereupon the partially assembled counter top may be removed from the clamping frame and the bonding adhesive previously deposited in the open channel grooves permitted to harden and set. Fibrous filler boards may be employed to fill the space within the stiffening frame to further stiffen and strengthen the construction.

The metal facing sheet is provided with lip portions extending from the ends of the apron sections thereof which are folded over the adjacent inclined ends of the apron backing sections before the apron sections are shaped into formed position. When the apron sections have been shaped to extend substantially at right angles to the table section of the metal clad panel, the adjacent lip portions of the metal sheet will be in faceto-face contact and extend diagonally inwardly from each vertical corner of the formed counter top. A seam of soldering or welding metal is applied to the exterior surface of the joint defined between the adjacent lip portions, the molten metal seeping inwardly betweenthe adjacent faces of the lip portions to firmly bond the adjacent lip portions into integral union. The exterior surface of the metallic seam may be burnished or polished to .give the corner a roundedand finished appearance.

Counter tops as 'thus constructed present a metal faced table section having a raised rim formation which may extend around all the edges or any selected number of thedge'sof the'table section. -The rim formation enhances the appearance of the construction, and serves torrevent liquids or solids on the table section from overflowing to the floor. The metal faced apron sections present smooth and rounded corners free of crevices or visible joints. The inwardly extending metal flan'ge sections present a 'mitered joint between the adjacent ends thereof, which joint can also be=boveredby a seam o'f soldering 'orweldin'g'meta'll. The inturned flange sections present a finished appearance and are designed to extend inwardly a sufficient distance so as 'to be at least partially concealed by the structure upon which the counter top isto be supported.

F 'The fibrousbacking'sections bonded to the rear face of the metal facing'sheet prevent'wrinkling, warping or other undesired distortions of the metal sheet during shaping'and bending thereof into counter top form, and in'ad'dition insures stiffness, strength and rigidity to the construction, provides a sound deadening effect so that the metal facing surfaces 'will not reverberate or produce a metallic ring when drummed upon, and in addition permits the use of a relatively light gauge metal facing sheet which can be worked and shaped with relative ease. The framingstrips snuglyfitted within the U-shaped cavity-defined bythe apron'sections and the ad- .jacent inturned flange sections, and the filler boards fitted within the confines of the stiffening frame, further enhances the rigidity and strength of the construction without substantially increasing its weight. The counter top construction hasall the exposed surfaces thereof covered by an unbroken metallic layer which y may be made from bright metal and thus can be easily cleaned and kept in a highly'sanitary con- I dition.

An object of this invention is to provide an improved counter top construction which can be manufactured at -a relatively low cost, which pr'esents a table section bordered by a raised rim formation and depending apron sections whose exposed surfaces are covere'dby a continuous and unbroken metal facing free of visible joints; providing-a counter top which is durable, strong and lasting in-use andyet relatively light 'in weight,

and which is attractive and pleasing in appear- Other objects and advantages of this invention will become apparent as the disclosure proceeds.

Although the characteristic features of the invention will be particularly pointed out in the claims-appended hereto, the invention itself, and the manner in which it may be carried out, may

"be better understood'by referring to the follow- 4 Y formation extending around the table section thereof.

Fig. 1A is a perspective view of a modified form of the counter top construction having the rim formation extending around only three sides of the table section.

Fig. 2 is an underside view of the improved counter top construction which illustrates certain structural details thereof.

Fig. 2a shows a fragmentary cross-sectional detail of the corner construction as the same appears when viewed along line 2a2a of Fig. 1.

Fig. 2b shows another fragmentary cross-secnorm detail ofthe corner construction as the same appears when viewed along line 2b-2b of *Fig. "1A.

"construction as the "same would appear when viewed along line '4A-4A of Fig. 1A.

Fig. 5 is a plan view of the rectangular metal sheet from which the metal facing surfaceso f the counter top construction is formed, this view showing the sheet after the top surface thereof has beenfpolis'hed and after the corner cutting operations have been performed thereon.

Fig. 5A is a fragmentary perspective view of a corner portion of the metal facing sheet shown in Fig. 5 after the lipportion's thereof have been bent upwardly.

Fig. 6 is a plan view of the fibrous backing sections, this view showing one method of connecting the sections in proper spaced relationship for application to the formed metal facin sheet.

Fig. -6A is a plan view of a one-piece fibrous backing panel with'the backing sections thereof separated by formed grooves, this view illustrating a modified method of retaining the backing sections in their proper spaced relationship for application to the metal facing sheet.

Fig. I is an enlarged longitudinal cross-sectional view of the backing panel as the same would appearas viewed along line l! of Fig-6.

Fig. 8 is an enlarged transverse cross-sectional view of the backing panel assembled from con- "nectedbackingsectionsas the same would appear when viewed along line 8-8 of Fig. 6.

Fig. 8A is an enlarged transverse cross-sectional View of the 'modified backing panel as the same would appear when viewed along line 8A--8A of Fi 6A.

Fig. 9 is an enlarged fragmentary cross-sectional view of the backing panel of Fig. 6, this view particularly showing the adjacent backing sections connected by a corrugated staple fastener as the same would appear when viewed along line 99 of Fig. 6. Fig. 9A is anenlar'ged fragmentary cross-sectional view of the backing' p'anel as shown in Fig. 6A, thisview particularly showing the connecting necks for connecting adjacent backing sections as the same would appear when viewed along line SA-SA of Fig. 6A.

Fig. 10 is a plan'view of the partially assembled "counter top construction showing the fibrous backing panel as applied and bonded to the metal facing sheet.

Fig. 11 is a plan view of the metal clad panel at a further stage of assembly and as the same would appear when viewed over the metal facing side thereof, this view particularly showing the rim formation impressed into the metal facing sheet to surround the table section thereof.

Fig. 11A is a plan view of the modified metal clad panel at a further stage of assembly, this view particularly showing the rim formation impressed along three sides of the table section of the metal sheet.

Fig. 12 is an enlarged fragmentary longitudinal cross-sectional view of the metal clad panel as the same would appear when viewed along line l2-l2 of Fig. 11 and Fig. 11A, this View additionally showing in cross-section and in elemental form, the cooperating forming dies used in shaping the rim formations extending along the side edges of the table section.

Fig. 13 is an enlarged fragmentary transverse cross-sectional view of the metal clad panel as the same would appear when viewed along line I3I3 of Fig. 11, this view additionally showing in cross-section the cooperating forming dies used in shaping the rim formations extending alon the front and rear edges of the table section of the counter top shown in Fig. 1.

Fig. 13A is an enlarged fragmentary transverse cross-sectional view of the modified metal clad panel as the same would appear when viewed along line I3AI3A of Fig. 11A, this view showing a cross-section of the forming die used in shaping the front rim formation of the modified counter top shown in Fig. 1A.

Fig. 14 is a perspective view of the counter top shown in Fig. l at a further stage of assembly, and wherein the apron sections have been shaped to extend at right angles to the table section thereof.

Fig. 14A is a perspective View of the modified counter top shown in Fig. 1A. at a further stage of assembly, this view showing the apron sections shaped to extend at right angles to the table section thereof.

Fig. 15 is an enlarged fragmentary longitudinal cross-sectional view of the partially assembled counter top construction as the same would appear when viewed along line l5l5 of Fig. 14.

Fig. 16 is an enlarged fragmentary transverse cross-sectional. view of the partially assembled counter top construction as the same would appear when viewed along line Iii-i6 of Fig. 14.

Fig. 16A is an enlarged fragmentary transverse cross-sectional View of the modified counter top construction partially assembled as shown in Fig. 14A and as the same would appear when viewed along line I6AI 6A of Fig. 14A.

Fig. 17 is a rear face view of the counter top construction at a further stage of assembly and wherein a stifiening frame has been positioned under the inturned flange sections thereof, this view showing the clamping frame employed to retain the apron sections of the counter top in proper assembled relationship while the stifi'ening frame is secured in position.

Fig. 18 is an enlarged fragmentary longitudinal cross-sectional view of the partially assembled counter top as shown in Fig. 18, this view also showing the elemental details of the clamping '6 counter top, this view also showing elemental details of the clamping and holding frame as the same would appear when viewed along line l9l9 of Fig. 17; and

Fig. 19A is an enlarged fragmentary longitudinal cross-sectional view of the partially assembled modified counter to construction, this view additionally showing elemental details of the clamping and holding frame therefor as the same would appear when viewed along line l9-|9 of Fig. 17.

Similar reference characters refer to similar parts throughout the several views of the drawings and specification.

The improved counter top construction, as generally illustrated in Fig. l to Fig. 4A inclusive, comprises a metal clad table section a having front and rear apron sections b, and side apron sections 0. The lower edge of the front and rear apron sections 1) are each provided with an inturned flange section (I, and the side apron sections 0 are each provided with an inturned flange section e. The ends of the side apron sections 0 and the adjacent ends of the front and rear apron sections I) meet to form the vertical front and rear corners of the counter top construction. The adjacent ends of the inturned flange sections d and e meet to form a diagonal joint as shown more particularly in Fig. 2. The table section a and the surrounding apron sections b and c are reinforced and held in rigid position by a rectangular shaped stiffening frame 7 which seats under the inturned flange sections d and e of the construction, as shown more particularly in Figs. 2 to 4A inclusive. The space defined within the stiffening frame f may be filled with fibrous filler g which provides further reinforcement to the construction.

An important feature of this invention is the provision of a rim formation 71. which defines the peripheral contour of the table section a. In the counter top construction shown in Fig. l, the rim formation h extends along the front, rear and side boundaries of the table section a so as to completely surround and enclose the table section. In the modified counter top construction shown in Fig. 1A, the rim formation it is shown as extending along only the front and side boundaries of the table section a. The rim formation 71. serves to prevent spillage of materials from the table section a to the floor.

This improved counter top may be made in any desired dimension to provide a top construction for restaurant, bar and merchandise counters, for cabinets, tables and other supporting structures as may he desired. For purposes of illustration,

frame as the same would appear when viewed along line l8! 8 of Fig. 1'7.

Fig. 19 is an enlarged fragmentary transverse cross-sectional view of the partially assembled the improved counter top is shown in Fig. 1 and Fig. 1A as mounted upon a cabinet structure S. This counter top may be easily secured to either wood or metal supporting structures S by the application of screws or brackets and concealed fro-m view. The table section, the apron sections, the inturned flange sections and the rim formations present metal facing surfaces free from crevices and visible joints.

The exposed facing surfaces of this improved counter top construction can be economically manufactured from a single substantially rectangular sheet of bright metal such as stainless steel, aluminum alloy, Monel metal, magnesium alloy, tin, brass or copper, or ordinary sheet steel which is later to receive an enamel finishing coat. The metal facing sheet w is initially substantially rectangular in form, as indicated in dotted lines in Fig. 5,'and may be relatively thin metal, of

.7 rrdm :1s tb.-=30 igauge in thickness. As an initial step in the manufacture, the rectangular metal f'ac'ing-sheetw is firstrun through 'a sander or polisher to give one side of the "sheet its final and ultimate :polish I and finish.

'-Ihecorners"w' ofthe'reotangular metal sheet "are then'trimmed 'ofias shown in Fig. '5, which 'o'per'ation can bequickly performed'on a metal shearing press. Asthus'form'eii themetal facing "-sheet presents 7 a table section I, from and rear apron sections 2 defined by the generally parallel ex-tendingbe'nding lines3, and side apron sectio'nsl dfinedby the generallyzp'arallel extending bending lines 5. Thefrontand rearapron seetins 2 "-are each provided with 'a flange section "(i"defined by a bending line 1, and the side apron -'sec'tions rare eachprovided with a flange section 8 defined by a bending lin'e 9.

'A lip port-ion ifl' extends from each end of the frontand rear apron sections 2 and is defined by a bending 'line5' substantially in alignment "with th'e adjacent bending line-5. Each end of ach of the side apron sections A is also provided vv'ith"alipffm'rtion defined by a bending line 3' s'ubsta'ntially in alignment with the adjacent -bendirig'line '3. The adjacent lip portions N] and s H 'ar'e separated by a diagonally extending out l2 whichterminates at the adjacent corner of the table forming section Eachendedge 6 of-the f'rdntandrear'flange sectionsfi extends fromthe fadjacent "corner of the adjacent apron section "2"'-at ana'ngle'of approximately 45 with'respect the-adjacent bending line 1. Each end edge 8' of'each 'of the side flange sections 8 extends from tlie adja'cent corner 'of the adjacent side apr6n sec'tion'4 at an angle of approximately-45 "with respe'cflto :the'adjacent bending line 9.

It will be appreciated that the bending lines Zi'e'Jnd I, 5 and-9, 5 and 3' are the lines along 'whichthe -metal fa'cin'gsheet, as shown'i'n'Fig. 5, "will be bent infa later forming operation. These bending operations are performed only after the fibrou sbacking panel '70 has been bonded to the tear surface of the metalfacing-sheetw.

Thefibrousbacking'panel' p as shown in Figs. 6 to 5 9 A inclusive, 'maybe'formed of laminated plyftvood, hard pressed fiberboar'd, "pressed "composition board, or'like relatively strong fibrous sheeting commonly used in the building industry. 'The fibrous backing panel '11 is preferably approximately inchin'thickness'although it will be appreciated that the fibrous backing "panel may vary inthickness from as lo'wa's of an inchto A inch or more in thickness.

'The 'backing panel shown in Fig.6 comprises a tablebacking section 2| of generally rectan'gular form with'squ'are cut edges of a size to accurately cover the table in section of the metal sheet within the raised rim formationsh thereof. Sepfarately formed front and'rear'apron backing sectio'ns22 are provided of'a size'to accurately cover the inside face 'of the front'an'd rear 'apron'sec "tions 2 of the metal "facing sheet. Each end 28 of e'ach'ofthe apron backing sections 22 issliced on an incline so'as to present'an end-face which "extends at an angle of approximately 45 to the "metal 1 'a'ttaching "face of the apron backing "sec tion. That lorigitudin'al edge 26 of eachbfthe apron backing 'secti'ons'22 'Which is to be position'ed next adjacent the table backing section 2|, -'is also cut to "provide a slanting *fac'e edge 26 whichfp'artiallyextends at an 'a'ngle of ap- -ipro'xima'tely 45? to the metal attaching face of "tlie backingsecti'on.

separately formed side-apron backing sections 24 are providedof asize and: shape toaccurately cover the inside face of theside apron sections 4 ofthe metal-facing'sheet. *Each of the side apron backing sections 24-have the ends thereof cut on a slant so as to present end-facing edges 29inclined at an angle-of 45 with respect to the metal attaching face'of the apron section. Each apron backing section '24 has one longitudinal edge thereof "cut on a miter so as to present a n 'inclined edge face 2'! which may be slightly rounded and partially inclined at an angle "of appr6xi- 'ma'tely 45 to the -metal attaching faceof the apron section. 7

It will be noted, as shown in Figs-6, 7 and 8, that the tablebacking section 2| and theapron backing sections 22 and maybe separately cut and formed with a minimum waste dfhiaterial. These sections are then connected to- 'gether to provide a backing panel unit which will hang together when adhesively applied to the metal facing sheet w. These backing sections may be conveniently connected together when laid'fiat upon a Work bench provided with "suitable corner guide blocks 41 which permit convenient interfitting of the sections as shownin Fig. 6. The longitudinally extending inclined edge 26 of the front and rear apron backing sections 22 are each spaced from the adjacent edge of the table backing section 2| a specified distance to provide an open groove 23'therebetween. The

described. The inclined longitudinal edge 21 of each of the side apron backing sections 24 are also accurately spaced, as by the use of Wedge blocks 49 from the adjacent edge of the table backing section 2| so as to provide an open groove '25 designed to snuglyreceivethe adjacent edge -2| of the apron section when the counter top has been formed.

The front and rear apron backing sections 22 and the side apron backing sections 24, thus accurately spaced by the defined open grooves '23 and-25 from the adjacent edges of the'table backing section 2|, are temporarily connectedto the table backing section-2| by driving suitable fasteners such as a corrugated staple fastener 48 as shown in Figs. 6 and 9, into the adjacent edge portions of the sections. The spacing assembly of the table backing section 2| and the apron backing sections 22 and 24 may be quickly performed by the use of a simple jig arrangement, as illustrated in Fig. 6-in its elemental form. These sections can then be quickly connected together in their proper spaced relationship by driving a few removable fastener elements 58 into the adjacent edge portions thereof. The assembled backing panel as shown in Fig. 6 is now readyto be adhesively secured to the rear face of the metal facing sheet, as-illustrated in Fig. 10. The lip portions ID and H of the metal facing sheet may be bent upwardly to abut the adjacent end faces of the backing panel, thereby to insure accurate registry of the backing panel with the metal facing's'heet until the adhesive bond'therebetween has firmly set.

The fibrous backing panelp may also be formed from a one-piece substantially rectangularsheet of fibrous backing material to provide 'a panel 'as illustrated in Figs-6A, 7, -8A, and 9A, ;ready for attachment to the metal facing-sheet. In

making the shaped panel here shown, a rectangular backing sheet is provided, cut to the desired size to define the exterior longitudinal edges of the apron sections 22 and 24; The corners of the rectangular panel are then cut away on a corner notching machine, whose cutting knives are so arrangedas to out each end 28 of the apron backing section 22 and the adjacent end 29 of the adjacent apron backing section 24 on an incline so that the end face 28 and the end face 29 will extend at an angle of approxi mately 45 to the metal attaching face of these apron sections.

After the backing panel shown in Fig. SA has been corner notched as above indicated, the same is run through a grooving machine which operates to cut the open grooves 25 therein, The grooving wheels of this machine will also cut the adjacent side edges of the side apron sections 24 so that they will present inclined faces 21. This grooving machine is so adjusted that it will leave uncut necks 3| along each groove 25. A second grooving machine is employed, having one grooving wheel set to cut the open groove 23 which defines the front apron section 22 from the table backing section 2 I. This grooving wheel operates to leave uncut necks 3| along the open groove 23, so that the open groove is only shallow cut as at 23' over the limited length necks 3| as shown in Fig. 9A.

If a counter top as shown in Fig. 1 is to be constructed, an open groove 23 with spaced necks 3| will also be cut in the backing panel to define the rear apron section 22 from the adjacent rear edge of the table backing section 2|. To illustrate the flexibility of these operations, Figs. 6A and 8A show a continuous V-shaped groove 39 cut into the backing panel to define the rear apron section 22 from the adjacent rear edge of the table backing section 2|. A V groove 38 such as here shown would be applied to the backing panel in event a counter top construction is to be formed which has no rim formation along the rear edge of the table section as illustrated in Fig. '1A. The fibrous backing panel p, corner notched and grooved in the manner illustrated in Figs. 6A, 7, 8, 8A and 9A, will hang together as an integral unit, ready to be adhesively bonded to the metal facing sheet.

'The backing panel having the backing sections thereof connected by the staple fasteners 48, as shown in Fig. 6, is coated with a bonding adhesive on the metal attaching face thereof and the panel applied to the rear face of the prepared metal facing sheet as shown in Fig. 5. To facilitate proper registry of the backing panel, it is preferably desirable to upturn the lip portions II] and II of the metal facing sheet along the bend lines and 3 thereof. The lip portions I5 are then driven down to snugly overlie the adjacent inclined end faces 23 of the front and rear backing sections I and 2, and the lip portions II are driven down to snugly overlie the inclined end faces 29 of the side apron backing sections 24. The metal clad panels thus assembled as shown in Fig. 10 may be stacked together under pressure until the bonding adhesive has become fully set so as to tenaciously bond the backing sections to the metal facing sheet. The staple fasteners 48 can then be withdrawn from the backing panel, at which stage of the production the metal clad panel appears as shown in Fig. 10, ready for shaping into counter top form.

In event a backing panel constructed in the form as illustrated in Fig. 6A is employed, this backing panel is adhesively bonded to the metal facing sheet and the upwardly extending lip portions I0 and II of the metal sheet driven down to snugly overlie the adjacent inclined end faces 28 and 29 respectively of the adjacent apron backing sections. The metal clad panels as thus formed may be stacked under pressure until the bonding adhesive has become thoroughly dry. The metal clad panel is then again run through the grooving machines merely to remove the spaced connecting necks 3| which connect the apron backing sections to the table backing sections. It will here be particularly noted that the backing panel has been so formed prior to its application to the metal facing sheet, that the connecting necks 3| each present an under surface 32 which is spaced from the metal attaching face of the panel as shown in Fig. 9A. It will thus be noted that the connecting necks 3| do not become adhesively bonded to the metal facing sheet, and consequently the neck portions 3| can be easily and cleanly removed to leave clean continuous grooves 23 and free from interfering backing material particles. As thus constructed, the metal clad panel formed from the backing panel shown in Fig. 6A and bonded to the metal facing sheet shown in Fig. 5 will be ready for assembly operations.

Assuming a counter top is to be constructed having a raised rim formation it which is to extend completely around the table section a as shown in Fig. l, the metal clad panel as shown in Fig. 10 is placed in a die press which operates to deform the peripheral portions I3, I4 and I5 of the table section of the metal facing sheet as shown in Figs. 11, 12 and 13. In event a counter top is to be made without a raised rim formation along the rear edge thereof as shown in Fig. 1A, only the front and side peripheral portions I3 and I4 of thetable section 2| of the metal sheet is deformed as illustrated in Figs. 11A, 12 and 13A.

The rim forming operation may be performed in one or more stages as desired by the use of one or more die presses illustrated in elemental form in Figs. 12, 13 and 13A. The die press elements shown in Figs. 12 and 13 are designed to form the rim formations I3, I4 and I5 in the metal clad panel as shown in Fig. 11. The die press is provided with a press table 50 having a flat table surface 5| upon which the table backing section 2| is supported, and raised table surfaces 52 upon which the apron backing sections 24 are supported. The press is equipped with vertically reciprocable press blocks 53, each having a die face 54 designed to exert downward pressure as at 55 against the metal sheet directly over the open grooves 25 so as to bend and shape the peripheral side edge portions I4 of the metal table section I to the desired rim conformity. In the second die press operation, the table backing section 2| is supported upon the table surface 5| of the press table 55 and the apron backing sections 22 are supported upon the raised surfaces 56 thereof. A pair of reciprocating die blocks 51, each having a die face 58, operate to exert downward pressure as at 55 the front and rear marginal portions of the metal table section to form the rim facings I3 and I5 of the desired contour. The die blocks 53 and 51 are so formed as to merge the adjacent ends of the rim faces I4, I3 and I5 into a smooth and unbroken raised corner bead I3. If necessary, corner die blocks may be em- 15 ployed to insure the desired rounded and con essence i tinuo'ns; contour at the corners of 'therim formation it.

In. the rimming formation of' the'metal clad panel as shown in Fig; 11A, employed in forming the counter top construction shown in Fig. 1A, the side rim formations l4 may be formed on the diefpress as illustrated in Fig. 12 and above described; Since only the front edge of the table section 2| is to receive the rim formation, a die press as shown in Fig. 13A may be employed to shape the front rim formation. The table backing section 2| of the metal cladpanel is supported on the table surface i of the press table 56 and the front apron backing section 22 is supported upon the raised'table surface 56 thereof. The die block 51 having the die face 58 operates to shape the, front edge portion of the metal table section I to provide the inclined rim face I3. A die block 591' havinga flat die face 59 maybe provided to exert pressure against the table section I and rear apron section 2 of the metal sheet to hold the metal clad panel in proper position.

When the rim facing portions l3, I4 and- I5 have been formed'at' the peripheral boundary ofthe table section I of the metal facing sheet as illustrated in Figs; 11; Band 13, the metal clad panel-is in condition for'shaping into counter top form as illustrated in Figs. 14,- and 16. Immecrate-1y before the shaping operation, a strip of bondingadhesive may be placed within the grooves--23 'and 25. Thereup'onthe front and rear apron-sectioned and thes'ide apron sections 0 are bent to extend substantially at right angles to the tablesection: a. to provide the partially formed" counter topas illustrated in. Figs. 14,15 and-16. The: front andrear flange sections 01 and the side flange sections; e, are. also bent inwardly so; as -to extend substantially at right angles to their associated.gapro-nsections hand 0,. Thisoperation can be performed by hand. or by a simple shaping jig or fixture.

As thus formed, each open groove 23; will re,- ceivettheadjacenti edge portion, 26 of the apron backing section; 22i with the; inclined edge: snugly: seating: againstthe; under-face of the. raisedmetaltrim: l3 and. I5,- asgshownin Fig. 16; The ,open'grooves will. likewisegreceive the adjacent edge portion. 2]: of: the, apron backing sectionsfidwiththe inclinededge. 21 firmly abutting against: the rear.- face; of. the raised metal rim formations. I4 as; shown inFig. 15., Uponcompletion of the shaping operation, the adjacent,

metal lip. portions, ID, and, I I are ln face-to-face contact as, shown more particularly in Fig-., 2a. The metal flange section 6 may be bent inward.- ly along the bending line lto providea slightly rounded. corner 1. as shownin Fig. 16, and the metal flangev sections 8 may bev bent inwardly along their bending lines 9 to provide slightly rounded corners 9' as shown in Fig. 15.

The counter top. construction shown in Fig. 1A may be. similarly formed a'sv shown in Figs. 14A, 15' and 16A. As the. first step, abonding adhesive is deposited in the open grooves 23 and 25and in the V groove 3110f the metal cladpanel as shown in Figs. 11A, 1'2'and'13A, and'th'e front and rear apron sections b and the side apron sections ethen bent to extend substantially at right angles to the table section a. As thus formed the, inclined edge 26 of the front apron backing section 22 will snugly seat against and support the overlyingmetal rim formation t3; and the inclined edges 21 the side apron backing'sections- The V groove" 30 will: close to form a miteredjoint 1?!! as shown inFig; 16A, providinga counter-topi construction which has no raised rim adjacent the mitered joint 3H".v

It" will be appreciated that the construction" shown in Fig. 14A, the end portions M" of the side rim formations I l are shapedin the die press to taper off in a slightlyrounded contour as shown in Fig; 16A- It will also benoted that the rear' metal apron section Zattheflat edge of the table section'a'would preferably be made of slightly less height than the apron sections which are crowned by a. rim formation, as is readily apparent by referring to Fig. 16A; In the modified construction shown in Fig; 1A, the adjacent metal lip portions l0" and H will'also'be brought into faceto-face' contact, as shown more particularly in Fig. 2a, upon completion of the shaping opera-- tion.

The front and rear apron sections b and-the side apron sections 0- may be held-in their proper formed position by a clampingframe as illustrated'in' Figs. 17 to-19A inclusive; The clamping frame may be associated with a suitable work table 60 upon which the partially formed counter top construction is supported, the table havingassociated therewith a fixed clamping bar 6-] which may be fixed to the work table and an adjustable clamping bar 62 between which the front and rear apron sections 1) are clamped. Adjustment of the front clamping bar 62 may be effected by the-use of adjusting bolts "63 which are threaded into a fixedbarfil; By manipulat ing the head portions 65' of the bolts 63; theclamp bar 62, engagedby' the ends of the adjusting bolts '63, may be readily manipuated. The

side apron sections 0 may likewise be clamped between a fixed clamping bar 65 andganadjustable clamping bar 61, the adjustable clamping bar- A reinforcing and. stiffening frame I is then.

inserted under the inturned metal ,flangesections d and e as shown in Figs. 17 to. 19A inclusive...

This is preferably accomplished by providing. a.

pair of front and rear stiffening strips 36 which may be made of. wood or like fibrous material, each shaped to snugly fit within the U-shaped pocket defined by the adjacent apron section b and the flange section d. Each of the stiffening. strips 36- preferably extend along thefullv side face of the adjacent apronbacking. section. 22. The stiffening strips-36 may be coated with a bonding adhesive which upon hardening willv adhesively secure the stiffening strip to the adjacent faces of the metal flange section 6, apron backing section 22 and table backing section 2i. A pair of side edging strips 31, suitably shaped and coated with adhesive, are inserted withinthe pocket defined by the side flange sections e and side apron sections 0 as shown more partic-= ularly in Figs. 19 and 19A. The side stiffening strips 3''!- extend between the adjacent endsof the front and rear stiffening strips 36 so the adjacent ends of the stiffening strips may have a notched interlock and may be firmly secured together by screws or nails 39 to provide a relatively rigid reinforcing frame Reciprocal pressure blocks 12 may be provided to exert pressure against the inturned flange section d and e of the apron sections to force the rim formation it within the table groove 1 I, and thus assure a firm adhesive bond between the inclined edges 26 and 27 of the apron backing sections and the adjacent rear face of the metal rim formations I3, l4 and I5. Where the counter edge is not provided with a raised rim formation, no table groove need be provided as shown in Fig. 19A, the adjacent pressure block 12' serving only to efiect a firm adhesive bond at the mitered joint 30'.

Before the partially assembled counter top is removed from the clamping frame as shown in Figs. 17 to 19A inclusive, it is desired to secure the inturned flange sections at and e and to the adjacent framing strips 36 and 31 as by screws or nails 39, which thus serve to hold the flange sections d and e and the apron sections b and c in proper assembled relationship until the bonding adhesive at has fully set. If no bonding adhesive a: is used, a sufficient number of space screws or nails 39 are employed to maintain the construction in assembled position after removal thereof in the clamping frame.

To further stiffen and strengthen the construction, the space defined within the stiffening frame 1 may be filled with a backing fiiler g as shown more particuluarly in Figs. 2 to 4A inclusive. The backing filler 9 may comprise a plurality of boards 40 formed of Wood or other fibrous material which may extend either longitudinally or transversely of the counter top construction. The filler boards 40 may have a notched interlocked connection 38 with the stiffening strips 35 and 3? as shown more particularly in Figs. 3, 4 and 4A, and spaced to permit expansion.

Since all the exposed faces of the metal surfacing sheet have been polished while the sheet was in fiat form as shown in Fig. 5, the only remaining operation to give the counter top construction its final finished appearance is to apply a seam 45 of soldering or welding metal to the vertical corners as shown in Figs. 1, 1A and 2a. The molten solder or welding metal will seep in between the adjacent faces of the inturned lip portions If] and l l of the metal sheet so as to integrally bond the lip portions Ill and. i I together over a substantial surface area, providing a corner construction of great strength. The exterior surface of the metal seam 55 may be burnished and polished to provide a smooth and rounded corner, free of cracks or visible lines of juncture. A seam of soldering or welding metal may also be applied to the adjacent edges 6' and 8' of the flange sections 6 and 8 as shown in Fig. 2 and Fig.2b to provide a smooth joint therebetween. The exposed surface of the metal seam may be polished or burnished to provide a smooth joint free of cracks or any visible line of juncture.

Counter tops may be made according to this invention in any desired width or length to satisfy any requirements. The apron sections 1) and may also be made of any desired height and the inturned flange sections cl and e may extend inwardly to any desired distance. The raised rim It may extend along only one edge of the table section, or may be formed to extend along two or' 14 three edges, or along all the edges of the table top section as may be desired. Thus this improved counter top construction may be provided with any desired number of raised edging rims and may be made in any desired size to'satisfy any dimensional requirements.

By reason of the fibrous backing sections which cover the entire area of the metal table section I, the front and rear metal apron sections 2, the metal side apron sections 4 and the raised rim formations l3, l4 and I5, an improved counter top construction is provided which is free from metallic sound or ring when drummed upon. The application of fibrous backing sections to the sheet metal prior to bending formation thereof, permitsthe use of a relatively light gauge metal facing sheet, which is prevented from wrinkling or warping during and after manufacture. By constructing the counter top in the manner above described, the exposed faces of the metal sheet may be sanded and finished rapidly and economically in its flat condition and before any forming operations are executed thereon, thus avoiding the more difficult and time consuming finished operations normally necessary after the counter top has been constructed. By forming the facing surfaces of the counter top from a single piece of sheet metal, crevices and cracks in which foreign matter may gather is substantially avoided. Extensive and time consuming welding andsoldering operations, heretofore necessary in the manufacture of metal clad counter tops as heretofore constructed, are also avoided.

Metal clad counter tops constructed as above described are unusually light in weight, since strength is achieved by the use of relatively light fibrous backing sections and wood or fibrous filler boards or strips. possesses unusual strength and rigidity and will not warp or deform. Since all exposed surface areas of the metal sheet, including the raised rim formation, are backed up by fibrous backing sections, the finished metal surface cannot readily be dented, even though formed of a relatively light gauge metal sheet. Counter tops may be manufactured in accordance with this invention to snugly fit and seat upon any desired supporting structure S. The inturned flange sections d and 6 may be made of sufiicient width so that the inner ends thereof and the associated securing screws or nails 39 are concealed by the structure upon which the counter top is supported.

Counter tops having rim formations may be manufactured in accordance with the teachings of this invention on a mass production basis at greatly reduced cost as compared with methods heretofore employed in the construction of metal clad counter tops. These improved counter tops are lasting in use, provide a construction of lasting utility, and are highly attractive and appealing in appearance and finish.

While certain novel features or" the invention have been disclosed herein, and are pointed out in the annexed claims, it will be understood that various omissions, substitutions, and changes may be made by those skilled in the art without departing from the spirit of the invention.

What is claimed is:

1. An improved counter top constructionhaving a table top section, a raised rim formation extending along the edges of said table section, and a plurality of apron sections depending from said rim formation, said counter top being formed from a one piece metal sheet shaped to form The counter top nevertheless 15': the; f ing surfaces for, said table section, rim, crmationandapr l t s. a dfi rou b c n sections bonded to said metal facing sheet to provide. back ppo he a le e t n rirn formation and apron sections of said metal. facing sheet, the adjacent ends of said apron backingsections beingmitre cut to provide spaced substantially parallel end faces presenting. an

open joint therebetween, said apron sections of the metalsheet having a lip portion at the adjacent e ds thereof extending; inwardly and in,

hugging contact with the adjacent mitre cut end of. the adjacent apron backing section, the adjacent metal lip portions being in face-to-face nta t,

2, Animproved counter top construction having atable top section, raised rim formations ex,- tendingalong a plurality of peripheral edges of said; table sect-ion, and apron sections depending frorn said; raised rim formations, said counter top being;- formed from a metal sheet shaped to form the facing. surfaces for said table section, raised rim formations, and apron, sections, fibrous backing sections bonded to said metal facing sheet to provide: backing support for the table se-ction,

metal facing surfaces supported and reinforced by fibrous material:

3..An improved. counter top construction having. atable top section, raised rim formations extending along the peripheral edges ofv said table. section apron sections depending from said. raised. rims .1."mations, and flange section extending inwardly from, said apron sections, said counter, top. being formed from a metal sheet forming the. facing surfaces for said table section, rim formations, apron s ctions and flange s ctions, and fibro ba ng Sections b n d to said metal facing sheet to provide backing support for the table section, rim formations and apronsectionsof said metal facing sheet, the adiacent end -:01 a d ron. back g. c ion being mitre. cut to. pr v e e e bs i ly p a l ndface p ent ng. an Open. m t d i int' betweemsaid apron sections of the metal sheet having a lip portion at the adjacent ends thereofextendingrinwardly and in hugging contact with the adjacent mitered end of the-adjacent apron backing section, the adjacent metal lip portions being in face-to-face. contact.

4. An improved counter top construction having a table top section, raised rim formations extending along adjacent edges of said table. section, and apron sections depending from said rim formations, said counter top being formed from a one piece metal sheet forming, the facing surfaces for said table top. section, rim formations and apron sections, a fibrous backing sec: tion bonded to said metal facing sheet providing backing support for the table section of said metal facing sheet, fibrous backing sections bondedtosaid metal facing sheet each providingback rim formations, said counter top; being formed;

- portions; into integral union.

5: An improvedcounter top-v construction hayinga tabletopsection, raised formations X1 tending along the peripheral edges, of" said ta J .9 an apron t e n in f from a; one piece metal sheet forming the faci surfaces for said, table. top section, rimllforiii 1 tions, and. apron, sections, a fibrous tablefbacking. section bonded to said metal. facing, sheet f viding, backing support for the, table. section, fibrous apron, back-ing sections bonded, to. said metal. sheet each providing a backing support for the adjacent apronsection of said. metal sheet, the upper edge of each of said apron backing sections being shaped. to, substantially. conforinf to the inner surface, contour. of the adjacent rim formation of said metal sheet and in substantial abutment thereagainst to provide, a backing sup-- port therefor, the adjacent, ends of said apron.

., backingsections presenting mitered joints there:

between, saidapron sections of the metal sheet having a lip portion at the adjacent ends thereof extending inwardly and in hugging contact with. the adjacent mitered end of the adjacent apron backing section, the adjacent metal lip portions being in face-to-face contact, and a seam of bonding metal covering the exterior joint between said inturned lip portions bonding said lip por tions into integral union, the space defined within said'apron sections being'filled with fibrous filler providing a light weight counter top presenting-- finished metal facing surfaces supported andreinforced by fibrous material. V 6. An improved counter top construction having a table top section, raised rim formations extending along the peripheral edges of said-table section, apron sections depending from said rim formations, and flange sections extending inwardly from said apron sections, said counter top'being formed from a one piece metal sheet" ends of said apron backing sections being mitre.

cut to provide spaced substantially parallel end faces presenting an open joint therebetween, said apron sections of the metal sheet having a lip portion at the adjacent ends thereof extending inwardly and in hugging contact with the adjacent mitered end of the adjacent apron backing section, the adjacent metal lip portions being in face-to-face contact, and a stiffening frame formed from stiffening strips of fibrous material seating within the pocket formed, b y'the adja:

cent apron sections and associated flange sections providing a counter top presenting finished metal facing surfaces supported and reinforced by said backing sections and stiffening frame.

7. An improved counter top construction having a table top section, raised rim formations extending along adjacent peripheral edges of said table section, and apron sections depending from said rim formations, said counter top being formed from a one piece metal sheet forming the facing surfaces for said table section, rim formations and apron sections, a fibrous backing section bonded to said metal facing sheet providing a backing support for the table section of said metal facing sheet, and fibrous apron backing sections bonded to said metal sheet each providing a backing support for the adjacent apron section and the adjacent rim formation of said metal sheet, the adjacent ends of said apron backing sections being mitre cut to provide spaced substantially parallel end faces presenting an open joint therebetween, each of the apron sections of the metal sheet having a lip portion at the end thereof extending inwardly and in overlying contact with the adjacent mitered end of the adjacent apron backing section, the adjacent metal lip portions being in face-to-face contact, and a seam of bonding metal covering the exterior joint between said inturned lip portions bonding said lip portions into integral union.

8. An improved counter top construction having a table top section, raised rim formations extending along the peripheral edges of said table section, apron sections depending from said rim formations, and flange sections extending inwardly from said apron sections, said counter top being formed from a one piece metal sheet shaped to form the facing surfaces of said table section, rim formations, apron sections and flange sections, a fibrous backing section bonded to said metal facing sheet providing backing support for the table top section of said metal sheet, fibrous apron backing sections bonded to said metal sheet each presenting a backing support for the adjacent apron section and the adjacent rim formation of said metal sheet, the adjacent ends of said apron backing sections being mitre cut to provide spaced substantially parallel end faces presenting an open joint therebetween, each of said apron sections of the metal sheet having a lip portion at each end thereof extending inwardly and in overlying contact with the adjacent mitered end of the adjacent apron backing section, the adjacent metal lip portions being in face-to-face contact, and a seam of bonding metal covering the exterior joints between said inturned lip portions bonding said lip portions into integral union.

9. An improved counter top construction hav ing a table top section, raised rim formations extending along the peripheral edges of said table section, apron sections depending from said rim formations, and flange sections extending inwardly from said apron sections, said counter top being formed from a one piece metal sheet forming the facing surfaces for said table top section, rim formations, apron sections and flange sections, fibrous backing sections bonded to said metal facing sheet to provide backing support for the table section; apron sections, rim formations,

and flange sections of said metal facing sheet, the adjacent ends of said fibrous backing sections being mitre cut to provide spaced substantially parallel end faces presenting an open joint therebetween, said apron sections of, the metal sheet having a lip portion at the adjacent ends thereof extending inwardly and in hugging contact with the adjacent mitered end of the adjacent apron backing section, the metal lip portions being in face-to-face contact, and a seamof bonding metal covering the exterior joint between said inturned lip portions bonding said lip portions into integral union, a stiffening frame formed from stiffening strips of fibrous material seating within the pocket formed by the adjacent apron sections and associated flange sections, the space defined within said stiffening frame being filled with fibrous filler providing a counter top presenting finished metal facing surfaces supported and reinforced by said backing sections, stiffening frame and fibrous filler. GLENN H. NORQUIST.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 902,700 Vance Nov. 3, 1908 1,145,681 Harrison July 6, 1915 1,440,615 Meyercord Jan. 2, 1923 1,524,897 Weil Feb. 3, 1925 1,731,131 Hall Oct. 8, 1929 1,826,618 Landaw Oct. 6, 1931 1,852,342 Ash Apr. 5, 1932 1,875,864 Gibian Sept. 6, 1932 1,916,435 Ott et a1 July 4, 1933 1,946,917 Ross Feb. 13, 1934 1,951,608 Gunn Mar. 20, 1934 1,995,543 Kaser Mar. 26, 1935 2,149,882 Clements Mar. 7, 1939 2,277,752 Frey Mar. 31, 1942 2,297,133 Burkhardt Sept. 29, 1942 2,378,402 Geimer June 19, 1945 

